Apparatus for forming sheet material



y 1968 L. T. TAPSCOTT APPARATUS FOR FORMING SH E ET MATERIAL s Sheets- Sheet 1 Filed Feb. 16, 1966 FIG. 1

FIG. 5

- w T E RT 3 M m m ,m v T mT A T" Y O m L Y By; {I Jl y 1968 L. r. TAPSCOT'T v APPARATUS FOR FORMING SHEET MATERIAL 3 Sheets-Sheet 13 Filed Feb. 16, 1966 INVENTOR. LEROY T. TAPSCOTT ATTORNEYS y 7, 1958 L. T. TAPSCOTT 3,381,562

APPARATUS FOR FORMING SHEET MATERIAL Filed Feb. 16, 1966 5 Sheets-Sheet s INVENTOR. LEROY T. TAPSCOTT ATTORNEYS United States Patent This invention relates to apparatus in which a pair of forming members are closed together to carry out a forming operation on sheet stock and, more particularly, to

devices of that type wherein the forming members revolve and reciprocate respectively and close together in each cycle to repeat the forming operation while the sheet is moving.

It is the practice in the manufacture of tabulating cards to subject sheet stock of extended length to a series of forming operations whereby the individual cards are punched with appropriate holes and given the desired outline, which is usually rectangular with rounded corners. One of the immediate purposes of the present invention is to provide high-speed means for accurately cutting these configurations in the stock and particularly for forming the rounded corners at one point in the manufacturing process. In its developed form described herein, however, it will be apparent that the invention is quite suitable for carrying out any one of a number of other forming operations, such as cutting, punching, embossing, creasing etc., on a variety of sheet materials including paper, sheet metal, plastic, and so on. Therefore, it is appropriate to describe the general class of devices of which the present apparatus is one as those wherein a pair of forming members are closed together cyclically by drive means from opposite sides of sheet stock to repeat forming operations on the stock at a station through which the sheet moves in its own plane.

The improvement of the invention comprises first displacement means for revolving the first forming member on one side of the plane of the sheet in a circular path passing tangentially through the station and parallel to the direction of motion of the sheet. Second displacement means are included for reciprocating the second forming member on the other side of the plane of the sheet in a path passing linearly through the station parallel to the direction of motion of the sheet. In accordance with the invention, synchronizing means are included which interconnect the two forming members and drive means so that in each revolution and full reciprocation they pass through the station at the same speed and in the same direction as the sheet and close together about the sheet to effect the forming operation. In a preferred form of the invention, the sheet moves linearly at a constant velocity and the synchronizing means continuously orients the forming members so that they face one another and maintain the same variable position along the linear path of movement of the sheet.

It is possible to operate a device of this construction at a very high rate of speed so that many hundreds of the forming operations are carried out per minute on a very rapidly moving sheet. Many conventional forms of this class of apparatus cannot approximate such operating rates because their revolving forming member does not follow a true circular path and stops fully at the forming station when it closes against the other forming member.

While the forming members of some other known designs move circularly at rapid speed, they turn into engagement in the manner of dies on opposed rolls without the strictly linear relative movement during closure which is characteristic of the forming members of the present apparatus. For this reason thev forming operation carried out by those known designs is less controllable and often less accurate than that done in accordance with the inven- 3,381,562 Patented May 7, 1968 tion. It is also a feature of the rapid operation of the form ing members in the present apparatus that they are notably free of vibration, which results principally from the fact that they revolve and reciprocate respectively on opposite sides of the moving sheet while in phase with one another and thus close together without any unnecessary displacement between them.

A preferred embodiment of the invention is described hereinbelow with reference to the accompanying drawings, wherein FIG. 1 is a section of the apparatus taken laterally through the sheet and showing the forming members closed together;

FIG. 2 is a section taken along the line 22 of FIG. 1;

FIG. 3 is a simplified view of the apparatus prior to closure of the forming members together;

FIG. 4 is a simplified view of the apparatus subsequent to closure of the forming members together;

FIG. 5 is a plan view illustrating the particular forming operation carried out in this embodiment;

FIG. 6 is a prospective view of one set of dies used to carry out this forming operation; and

FIG. 7 is an alternate form of one of those dies.

Referring first to FIGS. 1 and 2, the apparatus includes a frame 10 on which a stock-guiding idler roll 11 is rotatably mounted. For manufacturing tabulating cards, an extended length of appropriate sheet 12 of conventional card stock material is passed around the idler roll 11 so that its upper run moves at a constant velocity in a linear path to the left as seen in FIG. 2. The apparatus of the invention may be part of a larger machine wherein various forming operations are carried out sequentially on the sheet 12 and the particular stage of the present forming operation in the over-all process is not critical.

Drive means for this apparatus includes an input shaft 13 which is rotated by an ultimate source not illustrated in the drawings. The input shaft 13 is mounted in suitable bearings supported by the frame 10 and it carries a primary drive gear 14 shown in FIG. 2. The primary drive gear 14 in turn drives first driven gears 15 and 15 mounted on respective coaxial second shaft sections 16 and 16', and through intermediate gears 17 and 17 the first drive gears turn second driven gears 18 and 18' mounted on respective coaxial second shaft sections 19 and 19'. The first shaft sections 16 and 16 therefore rotate at the same angular velocity in a direction opposite to the second shaft sections 19 and 19. The first and second shaft 16, 16' and 19, 19 are parallel and disposed on opposite sides of the upper run of the sheet 12 as shown in FIGS. 1 and 2.

In accordance with the invention, the respective shafts 16, 16 and 19, 19' are adapted cyclically to close together first and second forming members (indicated generally by reference numerals 21 and 22 respectively) from opposite sides of the upper run of the sheet 12 to repeat forming operations thereon at a station (indicated in FIG. 2 generally by the reference numeral 23) through which the sheet moves longitudinally in a linear path at a constant velocity.

First displacement means are provided which includes a first support comprising a pair of first cranks 25 and 25 affixed coaxially to the respective first shaft sections 16 and 16 on opposite sides of the upper run of the sheet 12 as shown in FIG. 1. These cranks include corresponding counterweight portions 26 and 26 to maintain dynamic equilibrium and reduce vibrations during rotation. Trunnions 27 and 27 extend from the respective first cranks 25 and 25' toward one another along a common axis parallel to and spaced from the axis of the respective first shaft sections 16 and 16'. Through suitable bearings they rotatably support opposite sides of a body 29 of the first forming member 21. A two-part upper die block 30 is bolted to the body 29 and has a configuration and mode of operation described hereinafter for cutting sections of the edges of the sheet 12 at the station 23. By this construction, the first shaft sections 16 and 16' are adapted to revolve the first forming member 21, and particularly its die block 30, above the upper run of the sheet 12 in a circular path passing tangentially through the station 23 and parallel to the direction of motion of the sheet 12.

The previously mentioned second shaft sections 19 and 19 carry corresponding second cranks 33 and 33' which include respective counterweight portions 34 and 34'. Guide blocks 35 and 35 are rotatable on the corresponding second cranks 33 and 33 about a common axis parallel to and spaced from the axis of the second shaft sections 19 and 19. Movable track means are provided in the form of respective pairs of parallel rods 37 and 37 which extend slidably through holes in the corresponding guide blocks 35 and 35 and have nuts 39 threaded to their lower ends to limit their slidable movement upward through the guide blocks. The pairs of rods 37 and 37' are maintained perpendicular to the plane of the upper run of the sheet 12 at the station 23 in a manner described below.

A pair of parallel rails 41 and 41' constitute fixed track means mounted in the frame to each side of and just below the sheet 12 at the station 23. A body 43 of the second forming member 22 includes opposed tongue portions 44 and 44 which are slidable in the respective rails 41 and 41'. The various rods 37 and 37 pass slidably through holes in the body 43 of the second forming member and are afiixed at their upper ends to the body 29 of the first forming member 21. The second forming member 22 is therefore restrained by and slidable along both the rods 37 and 37' and the rails 41 and 41', and it includes a two-part lower die block 45 which is thereby reciproca-ble in a path passing linearly through the station 23 parallel to the direction of motion of the upper run of the sheet 12.

The various movements of the parts described above are synchronized during the operation of this apparatus due to the fact that the rods 37 and 37' interconnect the forming members 21 and 22 and thus remain vertical. They continuously orient the forming members 21 and 22 so that they face one another and maintain the same variable position one over the other along the linear path of movement of the upper run of the sheet 12. Synchronization is also achieved due to the equal spacing between the axes of the trunnions 27 and 27' and the first shaft sections 16 and 16' and between the axes of rotation of the {guide blocks 35 and 35' and the second shaft sections 19 and 19.

The operation of the apparatus is best described with reference to FIGS. 3 and 4. The cranks 25 and 25' rotate clockwise at a constant angular velocity while the cranks 33 and 33 rotate at the same angular velocity in a counterclockwise direction. The first support 21 is thereby revolved about the first shaft sections 16 and 16' and also rotates about its trunnions 27 and 27' so that its upper die block 30 always faces downwardly. The guide blocks 35 and 35' likewise revolve about the shaft sections 19 and 19' and at the same time rotate on the second cranks 33 and 33' so that one surface of the guide blocks is always facing upwardly. The rods 37 and 37 are carried around by the body 29 of the first support 21 and hence they slide vertically within both the guide blocks 35 and 35' and the body 43 of the second support 22. This causes the second support 22 to reciprocate horizontally and this motion is maintained in a straight line by the rails 41 and 41, with the lower die block 45 of the second support always maintained beneath the die block 30 of the first support.

As seen in FIG. 3, the upper die block 30 is moving in a circular arc downwardly toward the lower die block 45, and the latter is moving at an increasing rate to the left. Both approach the forming station 23 in this manner until they close together as shown in FIG. 2, and at that point the tangential velocity of the upper die block 30 and the linear velocity of the lower die block 45 (then at a maximum) are equal to the velocity of the sheet 12 moving through the'station 23. Consequently, the die blocks 30 and 45 close together in a straight-line relative motion Without any other displacement with respect to the sheet 12 at the instant the forming operation is carried out. The forming effected on the sheet is therefore extremely accurate and easily controlled from the standpoint of dimensional tolerance. It will be noted that the upper surface of the lower die block 45 is always flush with the underside of the upper run of the sheet 12 as it moves continuously to the left from the idler roll 11 as seen in FIG. 2, and hence that run of the sheet is given support by the block 45 against downward displacement out of its desired linear path of travel.

After the forming operation is accomplished, the upper die block 30 revolves upwardly and to the left away from the sheet 12 as shown in FIG. 4 and the lower die block 45 falls behind the sheet as its linear velocity decreases. With continued rotation of the cranks 25 and 25 and 33 and 33, the upper die block 30 is carried up and around to return toward the FIG. 3 position while the lower die block 45 is reversed to reciprocate to the right back through the forming station in a non-operative return stroke. All of these motions are balanced and dynamic equilibrium is maintained so that several hundred such forming operations can be effected per minute on the continuously moving sheet.

Turning now to FIGS. 5 to 7, one particular forming operation is illustrated along with appropriate dies for carrying it out. It is the purpose of this operation repeatedly to cut arcuate sections 50 and 50' from the opposite sides of the sheet 12 so that separation can later be carried out between them and produce rounded corners onthe tabulating cards so formed. To do this, a pair of male dies 51 and 51' are mounted on the respective sections of the two-part upper die block 30. The male die 51 is shown in FIG. 6 to include arcuate shoulders and a pointed edge 52. A female die is also provided which comprises pairs of cylinders 53 and 53' located on the respective sections of the two-part lower die block 45 to receive the male dies 51 and 51' respectively. The cylinders of each pair are fastened in position in tangential engagement with one another and their diameters correspond to the arcs of the shoulders forming the point 52 on the corresponding male die 51 or 51'. As the male dies 51 and 51 enter the forming station, they pass in a scissors-like fashion immediately adjacent the respective pairs of cylinders 53 and 53' and cut the sheet 12 in the configurations 50 and 50 shown in FIG. 5.

. An alternate form of the female dies is shown in FIG. 7 wherein a pair of adjoining oblong blocks 55 serve as each section of the two-part lower die block 45, and adjacent arcuate portions 56 on each pair of the oblong blocks are included to perform the same function as the cylinders in cooperating scissors-like with the male die 51.

I claim:

1. Apparatus wherein first and second forming members are cyclically closed together by drive means from opposite sides of a sheet to repeat forming operations thereon at a station through which the sheet moves in its own plane, the improvement which comprises (a) first displacement means for revolving the first forming member on one side of the plane of the sheet in a circular path passing tangentially through the station and parallel to the direction of motion of the sheet,

(b) second displacement means for linearly reciprocating the second forming member on the other side of the plane of the sheet in a path passing through the station parallel to the direction of motion of the sheet, and

(c) synchronizing means interconnecting the forming members and drive means so that in each revolution and full reciprocation of the respective forming members they pass through the station at the same speed and in the same direction as the sheet and close together about the sheet to effect the forming operation.

2. Apparatus according to claim 1 wherein the sheet is of extended length and moves longitudinally through the station in a linear path at a constant velocity, and the synchronizing means continuously orients the forming members so that they face one another and maintain the same variable position along the path of movement of the sheet.

3. Apparatus according to claim 1 wherein the forming members include die means for cutting sections from the edges of the sheet at the station.

4. Apparatus according to claim 1 wherein the first displacement means comprises a first support rotatable by said drive means about an axis spaced from and transverse to the direction of motion of the sheet at said station, said first forming member being rotatably mounted on the first support about an axis parallel to and spaced from the axis of rotation of the first support.

5. Apparatus according to claim 4 wherein the first support comprises a pair of first cranks coaxially positioned to each side of the station With the first forming member extending rotatably there'between transverse to the direction of motion of the sheet at said station.

6. Apparatus according to claim 1 wherein the second displacement means comprises a second support rotatable by said drive means about an axis spaced from and transverse to the direction of motion of the sheet at said station, guide means rotatable on said second support about an axis parallel to and spaced from the axis of rotation of the second support, movable track means slidable in said guide means and maintained perpendicular to the direction of motion of the sheet at said station, and fixed track means parallel to the direction of motion of the sheet at said station, said second forming member being restrained by and slidable along both said movable and fixed track means.

7. Apparatus according to claim 6 wherein the second support comprises a pair of second cranks coaxially positioned to each side of the station, the guide means comprises a pair of blocks rotatable coaxially 0n the respective second cranks, the movable track means comprises rods slidably mounted in the respective blocks, and the fixed track means comprises parallel rails disposed to each side of the station adjacent the plane of the sheet at the station.

8. Apparatus according to claim 1 wherein the first and second displacement means include respective first and second supports rotatable by said drive means in opposite directions at the same angular velocity about correspond ing parallel axes positioned on opposite sides of and coplanar with said station transverse to the direction of motion of the sheet at the station; said first forming member being rotata-bly mounted on the first support about an axis parallel to and spaced a given distance from the axis of rotation of the first support; said second diplacement means further comprising guide means rotatable on the second support about an axis parallel to and spaced said given distance from the axis of rotation of the second support, movable track means fixed to said first forming member and maintained perpendicular to all the aforementioned axes, and fixed track means mounted perpendicular to both said movable track means and all the aforementioned axes, said second forming member being restrained by and slidable along both said movable and fixed track means.

References Cited UNITED STATES PATENTS 2,136,210 11/1938' Hall. 2,544,527 3/ 1951 Crosland. 2,770,203 11/ 1956 Ooms. 2,857,966 10/1958 Sarka 833 15 X 3,121,361 2/1964 Kramer. 2,406,808 9/ 1946 Conner 83328 X 2,808,104 10/1957 Peterson 83320 3,242,785 3/1966 Schieven et al 83917 X 3,288,013 11/1966 Cochrane 83-328 ANDREW R. JUHASZ, Primary Examiner. 

1. APPARATUS WHEREIN FIRST AND SECOND FORMING MEMBERS ARE CYCLICALLY CLOSED TOGETHER BY DRIVE MEANS FROM OPPOSITE SIDES OF A SHEET TO REPEAT FORMING OPERATIONS THEREON AT A STATION THROUGH WHICH THE SHEET MOVES IN ITS OWN PLANE, THE IMPROVEMENT WHICH COMPRISES (A) FIRST DISPLACEMENT MEANS FOR REVOLVING THE FIRST FORMING MEMBER ON ONE SIDE OF THE PLANE OF THE SHEET IN A CIRCULAR PATH PASSING TANGENTIALLY THROUGH THE STATION AND PARALLEL TO THE DIRECTION OF MOTION OF THE SHEET, (B) SECOND DISPLACEMENT MEANS FOR LINEARLY RECIPROCATING THE SECOND FORMING MEMBER ON THE OTHER SIDE OF THE PLANE OF THE SHEET IN A PATH PASSING THROUGH THE STATION PARALLEL TO THE DIRECTION OF MOTION OF THE SHEET, AND (C) SYNCHRONIZING MEANS INTERCONNECTING THE FORMING MEMBERS AND DRIVE MEANS SO THAT IN EACH REVOLUTION AND FULL RECIPROCATION OF THE RESPECTIVE FORMING MEMBERS THEY PASS THROUGH THE STATION AT THE SAME SPEED AND IN THE SAME DIRECTION AS THE SHEET AND CLOSE TOGETHER ABOUT THE SHEET TO EFFECT THE FORMING OPERATION.
 3. APPARATUS ACCORDING TO CLAIM 1 WHEREIN THE FORMING MEMBERS INCLUDE DIE MEANS FOR CUTTING SECTIONS FROM THE EDGES OF THE SHEET AT THE STATION. 